A filter for air with a tubular filter body and an electrostatic pad prefiltering the air from the inlet

FILTER

The present invention relates to a filter intended particularly (but not necessarily exclusively) for use in a ventilator device for assisting respiratory function.

It is common practice for a patient on a ventilator in intensive care to receive nebulised drug therapy such as bronchial dilators and antibiotics to assist respiratory function. The patient will be connected to a ventilator through a breathing circuit and the drug will be administrated to them as a controlled and measured dosage. Exhaled air is then passed via the breathing circuit to the ventilator.

The exhaled air will entrain a quantity of the drug. It is important that this excess drug is removed from the airflow before it reaches the ventilator otherwise the flow transducers within the unit could become affected. An in-line filter is therefore provided in the breathing circuit for removing the drug. A filter is also essential to prevent the contamination of the local environment and to protect the staff from any adverse effects of the nebulised drugs.

Unfortunately, the filter will become blocked with the drug and other waste material during the course of this medical procedure. In turn, this will affect directly the performance and life of the filter. The filter must therefore be changed at regular intervals and before the build-up of waste material in the filter becomes too high to inhibit the airflow. The current practice is to change the filters when the pressure loss reaches 5 millibars (ideally 4.5 mbar). On current filter designs this point can be reached within 24-48 hours.

Clearly replacement of the filter involves the cost of its replacement. Additionally to install the replacement filter it is necessary for the breathing circuit of the ventilator to be “broken” and this can result in release of drugs into the local environment with risk of exposure to medical staff.

It is clearly desirable to provide a filter which requires replacement less frequently than conventional units.

According to a first aspect of the present invention there is provided an air filter comprising;

(i) a housing with an air inlet and a coaxial air outlet, and (ii) a filter material in the path of air flow from the inlet to the outlet, the filter material being formed as a tubular body positioned coaxial with said inlet and said outlet, said tubular body being located at one of its ends around the air outlet and being blanked at its end opposite the air outlet so that the blanked end faces the air inlet and said air flow is inwardly through the tubular body, wherein the air filter further incorporates an electrostatically charged material positioned at the blanked end of the tubular body and externally thereof to treat inlet air to the housing before it passes through the filter material, wherein the electrostatically charged material is in the form of a flat pad seated on the blanked end of the tubular body and being positioned directly facing the inlet and perpendicular to the direction of air flow through the inlet.

We have found that the provision of an electrostatically charged material within the air filter to treat incoming air serves to improve the life of the filter material. More particularly, the electrostatically charged material is capable of attracting (and retaining) both liquid and particles so as to prevent their further travel into the filtration medium. Furthermore, the electrostatically charged material may be absorbent and therefore retain moisture.

Preferably the electrostatically charged material is of larger cross-sectional size than the air inlet.

(followed by page 3a)

The electrostatically charged material may, for example, be a fibrous material. In particular, the electrostatically charged material may be a needled synthetic material inbued with an electrical charge during the course of manufacture. For example, the material may be produced from a combination of two different fibres (e.g. a 50/50 combination) which are then needled at high speed (e.g. using about 1500 needles per sq inch) to impart a substantial electrostatic force.

The filter material may be pleated, e.g. a pleated paper. Such a paper may comprise glass fibre. The filter material may be a HEPA filter.

The filter material is in the form of a tubular body and is located at one of its ends around the air outlet. At its opposite end, the tubular body is “blanked-off’ and the electrostatically charged material is provided at the blanked end (external of the body). The air inlet, the air outlet and the tubular body are all coaxial. The arrangement has the advantage that the electrostatically charged material (which may be in the form of a pad) causes the incoming air to diffuse, slow down and be diverted between the interior of the housing and the exterior periphery of the tubular body so that the air may then pass through the filter material.

According to a second aspect of the present invention there is provided a ventilator assembly having a breathing circuit incorporating an air filter according to the first aspect.

The term ‘comprising’ as used in this specification and claims means ‘consisting at least in part of. When interpreting statements in this specification and claims which include the term ‘comprising’, other features besides the features prefaced by this term in each statement can also be present. Related terms such as ‘comprise’ and ‘comprised’ are to be interpreted in similar manner.

The invention will now be further described, by way of example only, with reference to the accompanying drawings, in which:

3a (followed by page 4)

Fig 1 is a cross-sectional view of one embodiment of air filter in accordance with the invention.

The filter 1 illustrated in Fig 1 comprises a two-part housing 2 formed of a cup-shaped body 3 having an air inlet 4 and a closure arrangement (or “lid”) 5 having an air outlet 6. Cup-shaped body 3 and closure arrangement 5 are such that the air inlet 4 and the air outlet 6 are coaxial. Air inlet 4 is formed with an annular slot 7 for use in mounting the air filter 1 in a ventilation circuit.

Provided within the housing 2 is a tubular frustoconical body 8, formed of a filter material, an end cap 9 and a pad 10 of an electrostatic filter medium seated on end cap 9. More specifically, the lower (as viewed in Fig 1) end of body 8 locates around the air inlet 6 and is encircled by an annular locating lip 11 provided on the inner surface of closure arrangement 5. End cap 9 is provided at the opposite end of body 8 and has a peripheral flange 12 which locates the cap 9 over the upper end of body 8, thereby blanking that end. End cap 9 additionally has a central well 13 which

WO 2008/047108

PCT/GB2007/003948 projects a short distance into the upper end of tubular body 8. Finally, end cap 9 is provided with clips 14 which serve to retain pad 11 seated in position.

Tubular body 8 is preferably of a pleated material. This material is preferably silicon treated glass fibre. Pad 10 is preferably a needled synthetic material imbued with an electrical charge during the course of manufacture.

In use, the filter 1 is incoiporated in the breathing circuit of a ventilator which provides nebulised drug therapy for a patient More specifically, the filter 1 is located in the path of air exhaled from the patient and upstream of the ventilator. As such, exhaled air passes into the inlet 4 of the filter 1 as depicted by Arrow A.

The electrostatic pad 10 is in the direct path of air entering through the inlet 4 and provides a number of functions. Firstly, the electrostatic pad 10 causes air to diffuse, slow down and be diverted down between the inner surface of the housing and the outer peripheral surface of the frustoconical body 8. Secondly, the electrostatic charge on the pad 10 attracts both liquid and particles and thereby prevent their further travel through the filter. As such, the liquid and particles held in the pad 10 do not pass to the tubular filtration body 8. Thirdly, the electrostatic pad is an absorbent material and is therefore able to hold moisture. It is these second and third functions particularly that together contribute to an increase in life of the tubular filter body 8.

The filter 1 may be used in the breathing circuit until the pressure lost reaches a predetermined value, e.g. 5 millibars. At that time, the filter 1 will be removed and replaced by a new unit.

The invention is further illustrated by the following non-limiting Example.

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PCT/GB2007/003948

Example

A filter 1 as shown in the drawing was constructed in which (i) the electrostatically charged material 10 was a circular pad of TECHNOSTATIC media having a diameter of 47mm and a thickness of 2mm, and (ii) the tubular body 8 was a pleated HEPA filter having a height through which air could pass (i.e. excluding areas where the body was coated with glue for mounting in the filter) of 35mm and a pleat depth of Hmm. A similar (comparative) filter was also constructed but omitting the TECHNOSTATIC pad.

Each filter was then subjected to the following test protocol:

(i) Pressure drop (mbar) across the filter (i.e. between the inlet and outlet) was tested of air flow rates of 30, 60, 90 and 120 litres per minute. The results were recorded as “Pre-test”.

(ii) The filter was placed in a humidifier at 37°C for 24 hrs.

(iii) Pressure drop at 30, 60, 90 and 120 litres per minute was then measured. The results were recorded as “24 hr Hum”.

(iv) Nebulised Ventoline was then passed to the inlet at an air flow rate of 10 litres per minute for periods of 1, 10, 10 and 10 minutes (i.e. 31 minutes total) with short intervals in between. For this procedure a total of 3ml Ventoline was used.

(v) Pressure drop at 30, 60, 90 and 120 litres per minute were then measured and the results recorded as “31 min V”.

(vi) The filter was then placed in the humidifier at 37°C for 4 hours.

(vii) Pressure drop was then measured and recorded as “4 hr Hum”.

(viii) Steps (iv)-(vii) were then repeated.

(ix) The filters were then stored overnight in plastics bags to prevent drying out.

(x) Steps (iv)-(ix) were then repeated on four successive days.

The results are shown in Table I below:

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Table 1

Invention_Comparative

<td> Day 1</td><td> 30L/min</td><td> 60L/min</td><td> 90L/min</td><td> 120L/min</td><td></td><td> 30L/min</td><td> 60L/min</td><td> 90L/min</td><td> 120L/min</td>

<td> Pre-test</td><td> 0.61</td><td> 1.35</td><td> 2.05</td><td> 3.12</td><td></td><td> 0.69</td><td> 1.52</td><td> 2.38</td><td> 3.57</td>

<td> 24hr Hum</td><td> 0.68</td><td> 1.43</td><td> 2.26</td><td> 3.61</td><td></td><td> 0.80</td><td> 1.75</td><td> 2.74</td><td> 4.26</td>

<td> 31 min V</td><td> 0.71</td><td> 1.50</td><td> 2.56</td><td> 3.79</td><td></td><td> 0.80</td><td> 1.80</td><td> 3.09</td><td> 4.69</td>

<td> 4hr Hum</td><td> 0.65</td><td> 1.44</td><td> 2.51</td><td> 3.69</td><td></td><td> 0.79</td><td> 1.75</td><td> 2.99</td><td> 4.46</td>

<td> 31 min V</td><td> 0.64</td><td> 1.47</td><td> 2.51</td><td> 3.64</td><td></td><td> 0.79</td><td> 1.72</td><td> 3.00</td><td> 4.60</td>

<td> 4hr Hum</td><td> 0.64</td><td> 1.47</td><td> 2.49</td><td> 3.72</td><td></td><td> 0.79</td><td> 1.72</td><td> 3.08</td><td> 4.60</td>

<td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td>

<td> Day 2 31 min V</td><td> 30L/minin 0.68</td><td> 60L/min 1.49</td><td> 90L/min 2.50</td><td> 120L/min 3.68</td><td></td><td> 30L/min 0.84</td><td> 60L/min 1.90</td><td> 90L/min 3.18</td><td> 120L/min 4.82</td>

<td> 4hr Hum</td><td> 0.69</td><td> 1.53</td><td> 2.57</td><td> 3.75</td><td></td><td> 0.91</td><td> 2.09</td><td> 3.64</td><td> 5.48</td>

<td> 31 min V</td><td> 0.68</td><td> 1.57</td><td> 2.65</td><td> 3.94</td><td></td><td> 0.85</td><td> 1.90</td><td> 3.29</td><td> 5.01</td>

<td> 4hrHum</td><td> 0.75</td><td> 1.61</td><td> 2.71</td><td> 4.04</td><td></td><td> 0.97</td><td> 2.11</td><td> 3.66</td><td> 5.71</td>

<td> Day 3</td><td> 30L/min</td><td> 60L/min</td><td> 90L/min</td><td> 120L/min</td><td></td><td> 30L/min</td><td> 60L/min</td><td> 90L/min</td><td> 120L/min</td>

<td> 31 min V</td><td> 0.72</td><td> 1.63</td><td> 2.78</td><td> 4.10</td><td></td><td> 0.99</td><td> 2.19</td><td> 3.85</td><td> 5.97</td>

<td> 4hr Hum</td><td> 0.76</td><td> 1.71</td><td> 2.85</td><td> 432</td><td></td><td> 1.17</td><td> 230</td><td> 4.39</td><td> 63&gt;3</td>

<td> 31 min V</td><td> 0.83</td><td> 1.80</td><td> 3.06</td><td> 433</td><td></td><td> 1.15</td><td> 2.60</td><td> 4.57</td><td> . 7.10</td>

<td> 4hr Hum</td><td> 0.82</td><td> 1.78</td><td> 237</td><td> 436</td><td></td><td> 1.26</td><td> 2.88</td><td> 5.11</td><td> 7.83</td>

<td> Day 4</td><td> 30L/min</td><td> 60L/min</td><td> 90L/min</td><td> 120L/min</td><td></td><td> 30L/min</td><td> 60L/min</td><td> 90L/min</td><td> 120L/min</td>

<td> 31 min V</td><td> 0.85</td><td> 1.95</td><td> 3.26</td><td> 4.89</td><td></td><td> 1.16</td><td> 2.71</td><td> 4.84</td><td> 7.41</td>

<td> 4hr Hum</td><td> 0.92</td><td> 1.93</td><td> 3.17</td><td> 4.72</td><td></td><td> 131</td><td> 2.73</td><td> 4.88</td><td> 7.6</td>

<td> 31 min V</td><td> 0.87</td><td> 1.93</td><td> 3.26</td><td> 4.96</td><td></td><td> 1.27</td><td> 2.93</td><td> 530</td><td> 8.23</td>

<td> 4hr Hum</td><td> 0.69</td><td> 1.46</td><td> 2.48</td><td> 3.71</td><td></td><td> 0.90</td><td> 1.95</td><td> 337</td><td> 5.12</td>

<td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td>

<td> Day 5</td><td> 30L/min</td><td> 60L/min</td><td> 90L/min</td><td> 120L/min</td><td></td><td> 30L/min</td><td> 60L/min</td><td> 90L/min</td><td> 120L/min</td>

<td> 31 min V</td><td> 0.69</td><td> 1.56</td><td> 2.64</td><td> 3.90</td><td></td><td> 0.93</td><td> 2.07</td><td> 3.64</td><td> 5.57</td>

<td> 4hr Hum</td><td> 0.76</td><td> 1.65</td><td> 2.77</td><td> 4.11</td><td></td><td> 0.97</td><td> 2.18</td><td> 3.76</td><td> 5.71</td>

<td> 31 min V</td><td> 0.77</td><td> 1.71</td><td> 2.89</td><td> 4.25</td><td></td><td> 0.99</td><td> 2.30</td><td> 4.03</td><td> 6.16</td>

<td> 4hr Hum</td><td> 0.82</td><td> 1.77</td><td> 2.98</td><td> 443</td><td></td><td> 1.16</td><td> 2.44</td><td> 438</td><td> 6.63</td>

The results in the above table demonstrate the superior results obtained in accordance with the invention in terms of reducing the measured pressure drop values as compared to those obtained with the Comparative filter. Attention is directed particularly to the pressure drop values obtained at the end of day 5 using an air flow

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PCT/GB2007/003948 rate of 120 litres per minute. The filter in accordance with the invention had a pressure drop of 4.43 mbar. In contrast the Comparative filter demonstrated a pressure drop of 6.63 mbar.

In a test protocol such as that detailed above, a pressure drop value of less than 5 mbar (ideally less than 4.5 mbar) after 5 days testing at 120 litres per minute is the value required for a satisfactory filter.

What we claim is: